Air Operated, Electrically Heated Plural Component Proportioner
For spraying or dispensing 1:1 mix ratio materials, including epoxies and polyurethane
foam. For professional use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 3 for a list of models and maximum working pressures.
This model is field-configurable to the following supply
voltages:
230 V, 1 Phase
230 V, 3 Phase
380 V, 3 Phase
2,000 psi (14 MPa,140 bar) Maximum Fluid Working Pressure
120 psi (0.84 MPa, 8.4 bar) Maximum Air Working Pressure
Approvals:
Heated Hose Gun
50 ft (15 m)10 ft (3 m)ModelPart
246101
Purge
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311511G3
Warnings
Warnings
The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment.
Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols
appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the
manual, refer back to these pages for a description of the specific hazard.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
•Turn off and disconnect power cord before servicing equipment.
•Use only grounded electrical outlets.
•Use only 3-wire extension cords.
•Ensure ground prongs are intact on sprayer and extension cords.
•Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
•Read MSDS’s to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
•Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
•Protective eyewear
•Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
•Hearing protection
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•Engage trigger lock when not spraying.
•Do not point gun at anyone or at any part of the body.
•Do not put your hand over the spray tip.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
•Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
•Tighten all fluid connections before operating the equipment.
•Check hoses and couplings daily. Replace worn or damaged parts immediately.
4311511G
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
•Use equipment only in well ventilated area.
•Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
•Keep work area free of debris, including solvent, rags and gasoline.
•Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
•Ground all equipment in the work area. See Grounding instructions.
•Use only grounded hoses.
•Hold gun firmly to side of grounded pail when triggering into pail.
•If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
•Keep a working fire extinguisher in the work area.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to
the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
•Open a valve to relieve the fluid expansion during heating.
•Replace hoses proactively at regular intervals based on your operating conditions.
Warnings
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•This equipment is for professional use only.
•Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual when equipment is not in use.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
•Do not alter or modify equipment.
•Use equipment only for its intended purpose. Call your distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
311511G5
Warnings
WARNING
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
•Keep clear of moving parts.
•Do not operate equipment with protective guards or covers removed.
•Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
6311511G
Typical Installation, without Circulation
Typical Installation, without Circulation
Key for FIG. 1
AReactor Proportioner
BHeated Hose
CFluid Temperature Sensor (FTS)
DHeated Whip Hose
EFusion Spray Gun
FProportioner and Gun Air Supply Hose
GFeed Pump Air Supply Lines
* Shown exposed for clarity. Wrap with tape during operation.
8311511G
Moisture Sensitivity of Isocyanates
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
The amount of film formation and rate of
crystallization varies depending on the blend of
ISO, the humidity, and the temperature.
To prevent exposing ISO to moisture:
•Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
•Keep the Iso (A) Pump Lube system jar 3/4 filled
with clean Throat Seal Lubricant (TSL) 206995.
Change whenever fluid appears cloudy.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Keep Components A and B
•Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
•Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
•Never use solvent on one side if it has been
contaminated from the other side.
•Always park pumps when you shutdown.
•Always lubricate threaded parts with Part 217374
ISO pump oil or grease when reassembling.
Foam Self-Ignition
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
material MSDS.
Separate
NOTICE
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A
(isocyanate) and component B (resin) parts.
Changing Materials
•When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
•Always clean the fluid inlet strainers after flushing.
•Check with your material manufacturer for chemical
compatibility.
•Most materials use ISO on the A side, but some use
ISO on the B side.
•Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
311511G9
Component Identification
Component Identification
W
T
DD
AD
AI
ti8447a
R
AK
AA
AH
S
FF
GG
ti8448a
X
U
Y
V
AG
ti8481a
Z
FIG. 3: Typical Installation
10311511G
Key:
Component Identification
RMain Disconnect Switch - Controls power to all
circuits. It must be ON for proportioning unit to
operate. Temperature displays are lit when main
switch is ON.
SMain Air Filter - Filters system air supply.
TResin (B) Pressure Gauge - Displays pressure in
resin proportioning system (B side).
UResin (B) - Inlet Supply Valve
VResin (B) Fluid Y-Strainer
W ISO (A) Pressure Gauge - Displays pressure in
isocyanate proportioning system (A side).
XISO (A) - Inlet Supply Valve
YISO (A) Fluid Y-Strainer
ZISO (A) Pump Lube System - (A side only)
AH Resin (B) Proportioning Pump - Draws in and
dispenses a fixed volume of resin to gun.
AI Power-Lock
™
Hose Heat Connection - Connects
power to heated hoses.
*AJ Primary Heater Over-Temperature Switch -
Sends signal to temperature controller if heater
exceeds maximum temperature condition.
AK Resin (B) Pump Wet Cup - Access for daily wet
cup refill.
DD Air Inlet Ball Valve - (3/8 NPT male fitting)
FF ISO (A) Inlet - Fitting (1/2 swivel fitting)
GG Resin (B) - Inlet (3/4 swivel fitting)
* Components not shown.
AA ISO (A) - Packing Nut and Lube Cup - (A side
only)
*ABPressure Limit Switches - Factory set to turn off
air drive system when proportioning pump exceeds
designed operating pressure limit.
*ACPrimary Heater Thermocouple - Senses
temperature of primary heater and inputs that
information.
AD FTS Jumper Harness - Carries electrical signal
from FTS sensor in isocyanate hose to hose
temperature controller.
*AEAir Motor Reversing Switch - (Front of air motor)
Energizes and de-energizes air solenoid valve coils
to reverse direction.
*AFPrimary Heater - Heats material to required
dispensing temperature.
AG ISO (A) - (Isocyanate) Proportioning Pump -
Draws in and dispenses a fixed volume of
isocyanate to gun.
311511G11
Controls and Indicators
Controls and Indicators
AN
AM
AR
AK
34!24
/.
/&&
34!24
/.
/&&
AL
Key:
AK Primary Heater Switch - Controls and protects
primary heater. It must be ON and lit green for
primary heater to operate.
AL Hose Heater Switch - Controls and protects hose
heat circuit. It must be ON and lit green for hose
heater to operate.
AM Hose Temperature Controller - Controls
temperature of hose heat. Adjust set point to
desired temperature. From this point, the
temperature control is automatic. Displays current
temperature after time-out.
AN Primary Heater Temperature Controller - Controls
temperature of primary heater. Adjust set point to
desired temperature. From this point, the
temperature control is automatic.
AO Pump Mode Function Knob - Controls operation
of air drive system.
•OFF - Air drive system is off.
•ON - Must be in this position for unit to operate.
•START - Momentary position that starts the air
motor movement and illuminates green light in
switch.
AU
AS
AW
AQ
AV
34!24
/.
/&&
AO
AP
B
A
R
A
0
-
0
3
)
25.
0!2+
B
A
R
A
0
-
0
3
)
AT
AP Park/Run Switch -
•PARK - Use this position for shutdown. Stops air
motor at bottom of stroke with proportioning
pumps in retracted position when trigger is
pulled.
•RUN - Enables Air Motor Power
AQ Pump Directional Indicator Lights (Green) -
Indicates direction the proportioning pump travels.
Both lights are off when pump switch is OFF or
when either proportioning pump exceeds its
operating pressure limit switch.
AR Counter - Records cycle count of proportioning
pumps. One cycle count equals two strokes (one in
each direction). One cycle equals .028 gal. (.106 l).
AS Downstroke Air Pressure Regulator - Controls air
pressure to air motor during downstroke.
AT Downstroke Air Pressure Gauge - Displays air
pressure in air drive system during downstroke.
AU Upstroke Air Pressure Regulator - Controls air
pressure to air motor during upstroke.
AV Upstroke Air Pressure Gauge - Displays air
pressure in air drive system during upstroke.
AW Emergency Stop Switch - Shuts off electrical
power to pump control and both heat control
circuits.
12311511G
Pressure Relief Procedure
Pressure Relief
Procedure
1. Turn off feed pumps and agitator if used.
2. Turn PARK/RUN switch to PARK.
3. Trigger gun to relieve pressure.
4. Turn off air inlet valve.
5. Engage gun piston safety lock.
Flushing
Flush equipment only in a well-ventilated area. Do not
spray flammable fluids. Do not turn on heaters while
flushing with flammable solvents.
•Flush out old fluid with new fluid, or flush out old
fluid with a compatible solvent, such as toluene,
naptha, or mineral spirits before introducing new
fluid.
•Use lowest possible pressure when flushing.
•To flush entire system, circulate through gun fluid
manifold (with manifold removed from gun).
•Always leave hydraulic oil or a non-water based,
non-water absorbent fluid in system. Do not use
water.
ti2409a
6. Verify gun fluid manifold valves A and B are closed.
ti2421a
7. Close pump inlet supply valves.
Only use flush solvents that are compatible with Fluoroelastomer seals. Non-compatible solvents will damage seals and cause hazardous conditions, such as
high pressure leaks and pressure switch failure.
311511G13
Setup
Setup
Locate Reactor A-20
1. Locate Reactor A-20 on a level surface and bolt in
place to the floor with 3/8 in. (10 mm) bolts.
•Two bolts through the 2 in. (50 mm) deep caster
bushings in the rear.
•Two bolts through the 3-5/8 in. (168 mm) deep
caster bushings in the front.
2. Do not expose Reactor A-20 to rain.
3. If you need to move the machine, add
provided casters.
4. Lift with hoist only from bar spanning across top of
cart.
Determine Power Source
Reactor A-20 can be wired to 3 types of power source:
•230 Volt / 1 Phase
•230 Volt / 3 Phase Delta
Electrical Requirements
Improper wiring may cause electric shock or other
serious injury if work is not performed properly. Have a
qualified electrician connect power and ground to main
power switch terminals. Ensure your installation
complies with all National, State, and Local safety and
fire codes.
Also ensure that incoming power is disconnected and
locked out at the source.
NOTICE
Ensure main power source meets all electrical
requirements specified on nameplate of proportioning
unit. Also ensure main power source has a dedicated
fuse disconnect. Power cord is not supplied.
•380 Volt / 3 Phase WYE
(220 Volts to Neutral)
14311511G
Configure to Supply Power
Both cord connection AND jumper positioning
steps on page 16 must be completed.
Step One - Connect Electrical Cord
Setup
green to ground (GND). See page 16 for proper jumper
positions.
Disregard terminal numbers on disconnect switch
blocks. Wire to positions shown.
,
,
,
0%
Disregard terminal numbers on disconnect switch
blocks. Wire to positions shown. Terminals will
2
accept up to #8 AWG (10 mm
) conductors.
1. Remove and retain two screws from lower front
shroud and remove.
2. Connect main power cord to electrical console as
follows:
a. Feed power cord through strain relief (SR) on
right side of unit. Push black die release lever
(RL) down to release contacts block (PD) for
easy wiring.
b. Connect power leads to Power Disconnect
Switch (PD). Snap contacts block (PD) back
onto switch.
c. Tighten strain relief nut.
d. Strain relief accepts cords 0.59 to 1.0 in. (15-25
mm) diameter.
e. Connect ground wire to ground lug (GL).
, , ,.
,
ti8611a
.
'2.$
230V, 3 Phase Delta: Use a screwdriver to connect
three power leads to top terminals L1, L2, and L3.
Connect green to ground (GND). See page 16 for
proper jumper positions.
,
,
, , ,.
,
ti8612a
.
0%
,
'2.$
380V, 3 Phase WYE (as shipped from factory): Use a
screwdriver to connect three power leads to the top
terminals L1, L2, and L3. Connect neutral to N. Connect
green to ground (GND). See page 16 for proper jumper
positions.
ti8608a
RL
PD
SR
GL
.
, , ,
,
,.
,
.
,
ti8613a
0%
,
'2.$
3. Replace lower front shroud. Reinstall the two
screws retained in Step 1.
230V, 1 Phase: Use a screwdriver to connect two power
leads to the top terminals N and L2 positions. Connect
311511G15
Setup
Step Two - Reposition Power Jumpers
Find location of Power Jumpers.
Power Jumper
Location
ti8609a
For 230V, 1 Phase and 230V, 3 Phase Installations,
change jumper positions as shown below. Machine is
shipped with jumpers in the fail-safe 380 3Ø position.
1. Remove upper rear control cover screws and cover.
2. Move one red jumper from the storage positions to
the positions shown for your power.
•A flat-blade screwdriver can be used under the
ridge on the side of the jumper to remove them.
•Push the jumper firmly into the new position.
3. Replace rear cover and two screws.
Step Two
TB2
Terminal Blocks
Position red jumpers
(under back cover on
opposite side)
, , , .
679%
(as shipped)
, , , .
6$ELTA
, , , .
6
ti8610a
16311511G
Setup
Ground System
•Reactor: is grounded through power cord; see page
15.
•Spray gun: connect whip hose ground wire to FTS;
see page 18. Do not disconnect wire or spray without whip hose.
•Fluid supply containers: follow your local code.
•Object being sprayed: follow your local code.
•Solvent pails used when flushing: follow your local
code. Use only metal pails that are conductive.
Place them on a grounded surface. Do no place pail
on a nonconductive surface, such as paper or
cardboard, which interrupts grounding continuity.
•To maintain grounding continuity when flushing or relieving pressure, hold a metal part of spray gun
firmly to the side of a grounded metal pail, then
trigger gun.
Iso Pump Lubrication System
2. Connect and tighten B- supply hose (J) to 3/4 NPT
swivel fitting (GG) on B- inlet ball valve (U), and to
resin transfer pump.
U
J
GG
3. Connect and tighten A- supply hose (BB) to 1/2 NPT
swivel fitting (FF) on A- inlet ball valve (X), and to
isocyanate transfer pump. See F
ti8451a
IG. 3, page 10.
Air Supply Connection
Connect main air supply (F) to air inlet fitting (DD) at air
filter (S). Hose fitting requires a 3/8 NPT female fitting.
Use a minimum of 3/8 in. ID air line (not supplied)
to deliver air supply to proportioning unit. Use 1/2
in. ID hose if over 15 ft long.The main air supply
must be clean and free of oil and contaminants.
Setup
Prepare isocyanate pump lubrication system as follows:
1. Lift lubricant reservoir out of bracket and remove
reservoir from cap.
2. Fill reservoir 3/4 full with TSL; see Accessories
section in manual 311512.
3. Thread reservoir onto cap assembly and place it
into bracket.
The lubrication system is now ready for operation; no
priming is required.
Fluid Supply Connections
Connect material supply to inlets of proportioning unit as
follows:
1. Ensure the A- and B- inlet ball valves (U,X) on
proportioning unit are closed.
DD
F
S
ti8456a
311511G17
Setup
Connect FTS and Heated Dual Whip Hose
NOTICE
To prevent damage to probe, do not kink or
excessively bend hose. Do not coil hose
tighter than the minimum bend radius of 3 ft
(0.9 m). Do not subject hose to excessive
weight, impact, or other abuse.
1. Carefully extend FTS probe (H) into the
hose section from the proportioner. Do not
bend or kink probe. Insert in component A
(ISO) side of main hose for foam or polyurea systems.
2. Connect FTS (J) to whip hose (W).
3. Connect whip hose ground wire (K) to
ground screw on underside of FTS.
4. Connect fluid hoses to FTS (J).
To use 1/2 in. (13 mm) ID fluid hoses,
remove the adapters from the proportioner fluid manifold and install them in
the FTS swivel inlets.
5. Connect electrical connectors (D).
6. Connect air hose (C) to whip air hose (L).
7. Connect hose assembly cable (F) to FTS
cable (R). Slide insulator sleeves (S) over
connection. Leave slack (G) in cables as
stress relief, to prevent cable failure.
8. Check hoses for leaks (see your Heated
Hose manual).
D
K
B
To G u n
To Proportioner
R
F
S
G
B
FIG. 4: Connect FTS and Heated Dual Whip Hose
S
A
J
A
H
L
C
W
TI9581C
18311511G
Setup
Recirculation / Pressure Relief
Lines
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves
function as over pressure relief valves when set to
SPRAY. Lines must be open so valves can
automatically relieve pressure when machine is
operating.
If circulating fluid back to the supply drums, use high
pressure hose rated to withstand the maximum
working pressure of this equipment.
If Recirculating to Supply Drum: Connect high
pressure hose (R) to relief fittings (BA, BB) of both
PRESSURE RELIEF/SPRAY valves. Route hose back
to component A and B drums. Refer to manual 309852.
2. Assemble heated hose sections, FTS, and whip
hose; see manual 309572.
3. Connect A and B hoses to A and B outlets on
Reactor fluid manifold (FM). Hoses are color coded:
red for component A (ISO), blue for component B
(RES). Fittings are sized to prevent connection
errors.
FM
VV
WW
ti8444a
Manifold hose fittings (VV, WW) allow use of 1/4 in.
and 3/8 in. ID Reactor heated fluid hoses.
249508 - ISO (A) (moisture guard) red hose, 1/4 in. (6
mm) ID; #5 JIC fittings (m x f); 35 ft (10.7 m) long.
249509 - Resin (B) blue hose; 1/4 in. (6 mm) ID, #6 JIC
fittings (m x f), 35 ft (10.7 m) long.
R
BA
ti8441a
BB
R
Connect Heated Hose
See manual 309572 for detailed instructions for
Graco heated hoses.
The fluid temperature sensor (FTS) and whip hose
must be used with heated hose; see page 19. Hose
length, including whip hose, must be 60 ft (18.3 m)
minimum.
4. Connect cables (SS). Connect electrical connectors
(NN). Be sure cables have slack when hose bends.
Wrap cable and electrical connections with electrical
tape.
SS
NN
ti8444a
311511G19
Setup
Close Gun Fluid Manifold Valves
A and B
ti2411a
Connect Whip Hose to Gun Fluid
Manifold
Do not connect manifold to gun.
ti2417a
Pressure Check Hose
See hose manual. Pressure check for leaks. If no leaks,
wrap hose and electrical connections to protect from
damage.
20311511G
Initial Startup
Initial Startup
3. Turn both PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY.
Do not operate Reactor without all covers and shrouds
in place.
Fluid Temperature Sensor (FTS)
Calibration
Calibrate the FTS ONLY at initial startup (the first
time the unit is operated) and any time the hose
length changes.
1. Before turning on the unit, ensure all hoses and
cables are properly connected. To ensure that the
FTS in the hose is at the same temperature as the
heaters, keep heat off and store the hose FTS near
the machine for several minutes.
2. While holding down the temperature unit button
(Fahrenheit - “F” or Celsius - “C”) turn the Reactor
main power ON.
3. Hold the temperature unit button until temperature is
shown on the display. The fluid temperature sensor
is now correctly calibrated.
SB
SA
ti8442a
4. Open both fluid valves (FV).
FV
ti8449a
5. Start feed pumps. Do not start proportioner air
motor or pumps.
Load Fluid with Feed Pumps
The Reactor is tested with oil at the factory. Flush
out the oil with a compatible solvent before
spraying; see page 13.
1. Check that Setup process is complete; see page 14.
2. Turn on component B agitator, if used.
311511G21
Always provide two grounded waste containers to
keep component A and component B fluids separate.
6. Hold gun fluid manifold over two grounded waste
containers. Open fluid valves A and B until clean,
air-free fluid comes from valves. Close valves.
TI2484a
Initial Startup
Digital Temperature Controllers
NOTICE
Do not turn power on to the hose heat until after all
hose power connectors are connected.
The proportioner has two temperature controllers that
automatically manage the temperature for the primary
heater and the hose heat.
NOTICE
To prevent damage to primary heaters and hoses, do
not turn on heat controller switches next to temperature controllers until purging procedures are complete
and heater and hoses are filled with chemical.
To change or enter the set point, proceed as follows:
1. Ensure red main disconnect switch is ON.
Temperature Controllers will illuminate.
Heat Output
Alarm Normal
Hose Only
A1
A2A3
Controller Screens
Push the left side scroll button to cycle through the
following screens.
Home
“XXXX”
“_SP1”
“_SP2”
“Hxx.x”
“UNIT”
Current temperature
reading.
Set Point 1. Use arrow
keys to enter set point.
Set Point 2. Only shows
on Hose Controller.
High temperature deviation alarm. Leave set at
30°F (17°C).
This screen indicates
power output in percent.
Use the arrow keys to
select °F or °C.
2. Press and release Scroll button (A1). Display will
read “SP1”. Press and release Up (A2) or Down
(A3) button to display set point.
Do not change SP2; see Over Temperature Alarm
section.
Temperature controller normally displays actual
temperature. When illuminated, red “01” display at
upper left indicates controller is asking for heat. The
“01” disappears when liquid in heater or hose
reaches set point temperature. The “01” cycles on
and off to indicate temperature maintenance.
3. Press and hold Up (A2) or Down (A3) button to
increase or decrease value.
4. After set point is entered, press and release Up (A2)
and Down (A3) buttons together to display actual
temperature. Actual temperature will also display
after a time-out period.
5. To start heaters, turn green control power switch
from ON to START. Light within switch will
illuminate.
NOTICE
Controllers are factory programmed and are not field
programmable. If you encounter problems with a controller, order a replacement. Do not change any programmed parameters. Do not substitute with
controller from alternate supplier; its use may damage
equipment.The heater and hose controllers are not
interchangeable.
22311511G
Change Between Fahrenheit and Celsius
The temperature controller is factory-set to display in
Fahrenheit units.
To change to Celsius units:
1. Press and release Scroll button (A1) until Controller
displays “UNIT”.
2. Press and release Down button (A3) once to display
“F”.
3. Press and release Down button (A3) once again to
display “C”.
4. Press and release Scroll button (A1) twice.
Controller will display Celsius units.
To change back to Fahrenheit units:
1. Press and release Scroll button (A1) until Controller
displays “UNIT”.
Initial Startup
2. Press and release Down button (A3) once to display
“C”.
3. Press and release Down button (A3) once again to
display “F”.
4. Press and release Scroll button (A1) twice.
Controller will display Fahrenheit units.
311511G23
Initial Startup
Over Temperature Alarms
Both the fluid heater and the hose heat have over
temperature alarms that will turn off the heat zone if high
temperatures are detected. If this happens, the green
light in the switch for that heat zone will go out.
The fluid heater has a fixed temperature switch on the
aluminum heater that opens at 230 °F (110 °C) and
turns off the heat zone. The temperature switch will
automatically reset, but the heat zone will need to be
manually restarted. The over-temperature condition
should never happen unless the solid state relay
(165SSR) fails closed.
The hose heat uses the temperature controller alarm,
monitoring the hose thermocouple (FTS) to watch for
high temperature conditions. This alarm is controlled by
SP2 (Set Point 2) and is factory set for 30 °F (17 °C).
This means that the alarm set point is 30° (17 °C) over
the SP1 operating temperature set point. Under normal
conditions, the output 02 light will be lit on the hose
controller. This output holds the hose heat power
contact ON and lights the green light in the switch any
time power is available to heat the hose. If the hose
temperature reading is 30 °F (17 °C) (SP2 setting) over
the temperature set point (SP1), the output 02 light and
switch light will go out. Hose heat will only return after a
manual START of the control switch, after alarm
conditions are gone.
Hose Heat Manual Mode
If the hose temperature controller does not see the Fluid
Temperature Sensor (FTS), it will shut off the hose heat
and give a flashing error alternating between:
SbEr = Sensor break error
H20.0 = Heat output 20%
The hose can be manually heated by turning the hose
back on with the hose switch and green light. The
up/down arrows can be used to adjust the default 20%
power output.
There is no monitoring or alarm in manual mode. You
must monitor the temperature by inserting a probe
thermometer inside the hose insulation against the
hose. The thermometer will read 10-20 °F less than
actual fluid temperature. Repair the temperature sensor
or cable as soon as possible to avoid damaging the
heated hose.
The hose heat deviation alarm is controlled by the SP2
setpoint. This is factory set to 30 °F (17 °C) and should
not be changed. A loss of alarm function and loss of
automatic over temperature shut-down could result.
Fluid Heater Temperature Offset
The fluid heater has been calibrated to provide setpoint
temperature fluid under flow conditions. When the
machine is powered up and no heat has been turned on,
the heater display will read somewhat lower than the
hose display. This is normal. The hose display has no
offset and will always read the actual temperature at the
sensor in the hose.
24311511G
Initial Startup
Supply Wet-Cups with Throat
Seal Liquid
Pump rod and connecting rod move during operation.
Moving parts can cause serious injury such as
pinching or amputation. Keep hands and fingers away
from wet-cup during operation. Turn main power OFF
before filling wet-cup.
1. Component A (ISO) Pump: Keep reservoir (Z) 3/4
filled with TSL. Wet-cup piston circulates TSL
through wet-cup to carry away isocyanate film on
displacement rod. Change the fluid in the reservoir
when it becomes milky-looking.
2. Component B (Resin) Pump: Check felt washers
in packing nut/wet-cup (AK) daily. Keep saturated
with TSL to prevent material from hardening on
displacement rod. Replace felt washers when worn
or contaminated with hardened material.
AK
ti8448a
ti8610a
Z
311511G25
Spraying Setup
Spraying Setup
1. After reaching spray temperatures, engage gun
piston safety lock.
ti2409a
2. Close gun fluid manifold valves A and B.
ti2728a
5. Open air inlet ball valve (DD).
S
DD
ti8449a
6. Turn both air regulators (AU, AS, page 12)
counterclockwise to 0 pressure.
7. Turn RUN/PARK switch to RUN.
8. Turn Pump Mode Function knob to START.
9. Slowly increase each UP/DN air regulator setting by
alternating pattern 5-10 psi (0.035-0.07 MPa,
0.35-0.7 bar) at a time until the approximate stall
(static) pressure is achieved on fluid gauges (GA)
and (GB). Leave UP stroke regulator setting at
approximately 10 psi (0.07MPa, 0.7 bar) lower than
DN stroke.
3. Attach gun fluid manifold. Connect gun air line.
Open air line valve.
ti2543a
4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY.
SB
SA
ti8442a
GA
ti8441a
10. Open gun fluid manifold valves A and B.
ti2414a
GB
26311511G
Spraying Setup
11. Disengage gun piston safety lock.
ti2410a
12. Test spray onto cardboard. Adjust for desired fluid
pressure on the DN stroke with regulator (AS).
Briefly spray until the UP stroke indicator light is on
and increase the UP regulator setting until the fluid
pressure (GA, GB) matches the DN stroke pressure.
This compensates for feed pump pressure boost.
Pumps have fluid to air ratio of 17.5 to 1. Feed
pumps add 2X feed pressure boost to outlet
pressure (on the up stroke only).
13. Check A and B fluid pressure gauges (GA, GB) to
ensure proper pressure balance between A and B. If
imbalanced, see repair manual 311512.
Spray Adjustments
Flow rate, atomization, and amount of overspray are
affected by four variables.
•Fluid pressure setting. Too little pressure results in
an uneven pattern, coarse droplet size, low flow,
and poor mixing. Too much pressure results in
excessive overspray, high flow rates, difficult control,
and excessive wear.
•Fluid temperature. Effects are similar to when fluid
pressure setting is too high or too low.
•Mix chamber size. Choice of mix chamber is based
on desired flow rate within machine capability and
fluid viscosity.
•Cleanoff air adjustment. Too little cleanoff air
results in droplets building up on the front of the
nozzle, and no pattern containment to control overspray. Too much cleanoff air results in air-assisted
atomization and excessive overspray.
14. Equipment is ready to spray.
311511G27
Shutdown
Shutdown
1. Shut off Primary and Hose heat switches.
34!24
/.
/&&
2. Park component A pump. Turn PARK/RUN switch to
PA RK .
7. Check and fill wet-cups (AK, Z).
8. Follow gun shutdown procedure.
3. Follow Pressure Relief procedure; see page 13.
4. Turn Pump Mode Function knob to OFF.
34!24
/.
/&&
5. Turn Main Power Disconnect switch (R) OFF.
6. Close air inlet ball valve (DD) and fluid inlet valves
(X, U).
28311511G
Operation
Operation
Daily Start-up Procedure
The daily start-up procedures describe normal
operation. Assume that all temperature and
pressure settings have been previously set, but that
the heating system is not up to operating
temperature.
1. Check condition isocyanate lubrication system and
service as required. Change pump lubricant when it
shows signs of change to a milky color.
2. Ensure supply fluid is at correct temperature as
recommended by chemical system supplier. Ensure
individual chemicals are correctly agitated within
their drums/day tanks, and moisture protection
system is properly set for operation. Recirculate
heated fluid back to supply drums if necessary; see
page 31.
3. Turn on main air supply to transfer pumps.
11. Turn on primary heater switch past ON to START.
Ensure heater setpoint is correct. Wait for operating
temperature to be reached.
To prevent excessive pressure build-up in heated
hoses, always bring hoses and primary heater up to
operating temperature before turning on pump switch.
12. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY.
SA
SB
ti8442a
4. Pressurize transfer pumps and open A- and B-inlet
supply valves.
5. Open air inlet ball valve.
6. Switch ON main power disconnect switch.
7. Uncoil heated hose.
NOTICE
Uncoil heated hoses before turning on hose heater
switch to prevent overheating and hot spots within
hose.
8. Check that hose setpoint temperature is correct.
9. Turn hose heat control switch past ON to START.
Switch will illuminate.
10. The hose power controller automatically adjusts the
hose current to the hose to compensate for hose
length and ambient temperature. Wait for actual
hose temperature readout to match hose setpoint
temperature.
13. Turn PARK/RUN switch to RUN.
14. Turn Pump Mode Function switch to ON and
momentarily to START. Pumps will pressurize the
fluid according to air regulator pressure.
15. Check A and B fluid pressure gauges (GA, GB) to
ensure proper pressure balance between A and B. If
imbalanced, bleed off the high side with valves SA
and SB until balanced.
GA
ti8442a
GB
311511G29
Operation
16. Open gun fluid manifold valves A and B.
ti2414A
17. Disengage gun piston safety lock.
ti2410A
18. Test spray onto cardboard.
19. Observe isocyanate-A and resin-B gauges on up
and down strokes. Readjust upstroke pressure
regulator as required to ensure proportioning pump
pressure is equal on both the up and down strokes.
20. Equipment is ready to spray.
30311511G
Fluid Circulation
Fluid Circulation
Circulation Through Reactor
Read Warnings; see page 4. Do not circulate fluid
containing a blowing agent without consulting with
your material supplier regarding fluid temperature
limits.
To circulate through gun manifold and preheat hose; see
page 32.
1. Load fluid with feed pumps; see page 21.
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves
function as overpressure relief valves when set to
SPRAY. Lines must be open so valves can
automatically relive pressure when machine is
operating.
2. Route circulation lines back to respective
component A or B supply drum. Use hoses rated at
the maximum working pressure of this equipment,
see hose manual.
Do not turn on hose heat unless hoses are already
loaded with fluid.
7. Set both Air Regulator pressures to start at 15 psi
(1.0 bar).
8. Turn PARK/RUN switch to RUN.
9. Turn Pump Mode Function switch to START.
10. Recirculate until desired temperature reaches set
point.
11. Turn Pump Mode Function knob to OFF.
12. Turn on hose heat if hose is filled with fluid without
air pockets or solvent.
13. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY.
SA
SB
ti8442a
3. Set RECIRC/SPRAY valves (SA, SB) to RECIRC.
SA
BA
BB
ti8442a
4. Turn Main Disconnect Switch (R) ON.
5. Open air inlet ball valve.
6. Set temperature targets; see page 22. Turn on
heater.
311511G31
SB
For additional circulation information, refer to
manual 309852.
Fluid Circulation
Circulation Through Gun
Manifold
Read Warnings; see page 4. Do not circulate fluid
containing a blowing agent without consulting with
your material supplier regarding fluid temperature
limits.
Circulating fluid through the gun manifold allows rapid
preheating of hose.
1. Install gun fluid manifold (FM) on Part 246362
accessory circulation kit (CK).
2. Connect high pressure circulation lines (N) to
circulation manifold (CK). Route circulation lines
back to respective component A or B supply drum.
Use hoses rated at the maximum working pressure
of this equipment.
3. Follow Load Fluid with Feed Pumps procedure; see
page 21.
4. Turn Main Power Disconnect Switch (R) ON.
5. Open air inlet ball valve.
6. Set temperature targets; see page 22. Turn on
heater.
Do not turn on hose heat unless hoses are already
loaded with fluid.
7. Set both Air Regulator pressures to start at 15 psi
(1.0 bar).
8. Turn PARK/RUN switch to RUN.
FM
CK
9. Turn Pump Mode Function switch to START.
10. Recirculate until desired temperature reaches set
N
ti2767a
point.
11. Turn Pump Mode Function switch to OFF.
12. Close gun fluid manifold valves.
13. Reconnect gun to fluid manifold and air hose.
For additional recirculation information, refer to
manual 309818.
32311511G
Maintenance
•Check and add TSL to B side pump wet-cup daily.
•Check ISO lube bottle for significant discoloration or
crystallization daily. Replace with fresh TSL when
needed.
•Ensure ISO (A) pump is down and in PARK position
during every shutdown.
•Keep any ISO (A) fluid from being exposed to atmosphere to prevent crystallization.
•Remove inlet filter screen plug (V, Y) and clean
screens if increased unbalanced pressures between
A and B is noticed or as needed for fluids used. Also
clean after flushing.
•Close gun fluid shutoff valves when not in use.
•If using a Fusion Air Purge gun, add grease with
grease gun per manual.
Fluid Circulation
•Clean gun filter screens and mix chamber ports regularly, or when increased unbalanced pressures
between A and B is noticed. See gun manual.
•Use lithium grease or Iso Pump Oil on all threaded
fluid fittings on the “A” side.
311511G33
Technical Data
Technical Data
CategoryData
Maximum Fluid Working Pressure2000 psi (1.4 MPa, 140 bar)
Maximum Air Working Pressure120 psi (0.84 MPa, 8.4 bar)
Machine Maximum Power with hose9000 Watts
Voltage Requirement (50/60 Hz)
(230 V Nominal: 195-253 VAC)
(380 V Nominal: 338-457 VAC)
*Full load amps with all devices operating at maximum
capabilities with 210 ft (64.1 m) of hose.
**When a surge transient is applied to the power lines of the unit, heat to the hose may be interrupted and require the
hose heat switch to be manually cycled.
***210 ft (64 m) of heated hose will produce the maximum allowable heat capacity. 310 ft (94 m) of heated hose may
be used, but will have 25% less heat capacity.
34311511G
Technical Data
311511G35
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 311511
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2006, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 01/2011
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